Constellium Drives Digital and Modular Innovation for Smart Aluminum Automotive Structures with ARENA2036
Constellium (NYSE: CSTM) has announced the completion of its FlexCAR project in collaboration with ARENA2036, Germany's leading research campus for future mobility. The project, completed over five years with partners including Mercedes-Benz, Siemens, and Bosch, focuses on developing modular vehicle systems using aluminum solutions.
The company developed a modular sill concept using HSA6™ high-strength aluminum alloys with recycled content, designed to support various powertrains including electric and hydrogen fuel cell vehicles. Additionally, Constellium's previous Digital Fingerprint project with ARENA2036 created a digital twin system for tracking aluminum component performance throughout its lifecycle.
Constellium (NYSE: CSTM) ha annunciato il completamento del progetto FlexCAR in collaborazione con ARENA2036, il principale campus di ricerca tedesco dedicato alla mobilità del futuro. Il progetto, sviluppato in cinque anni con partner come Mercedes-Benz, Siemens e Bosch, si è concentrato sulla creazione di sistemi veicolari modulari utilizzando soluzioni in alluminio.
L'azienda ha sviluppato un concetto modulare di soglia basato su leghe di alluminio ad alta resistenza HSA6™ con contenuto riciclato, progettato per supportare diverse tipologie di propulsione, inclusi veicoli elettrici e a celle a combustibile a idrogeno. Inoltre, il precedente progetto Digital Fingerprint di Constellium con ARENA2036 ha creato un sistema di gemello digitale per monitorare le prestazioni dei componenti in alluminio durante tutto il ciclo di vita.
Constellium (NYSE: CSTM) ha anunciado la finalización de su proyecto FlexCAR en colaboración con ARENA2036, el principal campus de investigación de Alemania para la movilidad del futuro. El proyecto, desarrollado durante cinco años con socios como Mercedes-Benz, Siemens y Bosch, se centró en el desarrollo de sistemas modulares para vehículos utilizando soluciones de aluminio.
La compañía desarrolló un concepto modular de umbral utilizando aleaciones de aluminio de alta resistencia HSA6™ con contenido reciclado, diseñado para soportar diversas motorizaciones, incluyendo vehículos eléctricos y de pila de combustible de hidrógeno. Además, el anterior proyecto Digital Fingerprint de Constellium con ARENA2036 creó un sistema de gemelo digital para rastrear el rendimiento de los componentes de aluminio a lo largo de su ciclo de vida.
Constellium (NYSE: CSTM)은 독일의 미래 모빌리티 연구 선도 캠퍼스인 ARENA2036과 협력하여 FlexCAR 프로젝트를 완료했다고 발표했습니다. 이 프로젝트는 Mercedes-Benz, Siemens, Bosch 등 파트너들과 함께 5년간 진행되었으며, 알루미늄 솔루션을 활용한 모듈식 차량 시스템 개발에 중점을 두었습니다.
회사는 재활용 소재가 포함된 HSA6™ 고강도 알루미늄 합금을 사용한 모듈식 사이드실 개념을 개발했으며, 전기차 및 수소 연료전지 차량을 포함한 다양한 파워트레인을 지원하도록 설계되었습니다. 또한, Constellium과 ARENA2036의 이전 Digital Fingerprint 프로젝트는 알루미늄 부품의 수명 주기 전반에 걸친 성능을 추적하는 디지털 트윈 시스템을 구축했습니다.
Constellium (NYSE : CSTM) a annoncé l’achèvement de son projet FlexCAR en collaboration avec ARENA2036, le principal campus de recherche allemand dédié à la mobilité du futur. Ce projet, réalisé sur cinq ans avec des partenaires tels que Mercedes-Benz, Siemens et Bosch, s’est concentré sur le développement de systèmes modulaires pour véhicules utilisant des solutions en aluminium.
L’entreprise a développé un concept modulaire de bas de caisse utilisant des alliages d’aluminium haute résistance HSA6™ contenant des matériaux recyclés, conçu pour supporter différents types de motorisations, y compris les véhicules électriques et à pile à combustible hydrogène. De plus, le précédent projet Digital Fingerprint de Constellium avec ARENA2036 a créé un système de jumeau numérique pour suivre la performance des composants en aluminium tout au long de leur cycle de vie.
Constellium (NYSE: CSTM) hat die Fertigstellung seines FlexCAR-Projekts in Zusammenarbeit mit ARENA2036, Deutschlands führendem Forschungscampus für zukünftige Mobilität, bekannt gegeben. Das über fünf Jahre mit Partnern wie Mercedes-Benz, Siemens und Bosch durchgeführte Projekt konzentrierte sich auf die Entwicklung modularer Fahrzeugsysteme unter Verwendung von Aluminiumlösungen.
Das Unternehmen entwickelte ein modulares Schwellerkonzept mit HSA6™ hochfesten Aluminiumlegierungen mit recyceltem Anteil, das verschiedene Antriebsarten einschließlich Elektro- und Brennstoffzellenfahrzeuge unterstützt. Darüber hinaus hat Constelliums vorheriges Digital Fingerprint-Projekt mit ARENA2036 ein digitales Zwillingssystem geschaffen, um die Leistung von Aluminiumkomponenten über deren gesamten Lebenszyklus zu verfolgen.
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Insights
Constellium's FlexCAR project advances modular aluminum structures, potentially strengthening their position in the evolving automotive market.
Constellium's completion of the FlexCAR project with ARENA2036 represents a significant technological advancement in the automotive aluminum sector. The modular sill concept using HSA6™ high-strength aluminum alloys creates a flexible structural backbone capable of supporting multiple powertrain configurations, including both battery electric and hydrogen fuel cell systems. This positions Constellium strategically at the intersection of two major industry trends: vehicle architecture modularization and the transition to alternative powertrains.
Particularly noteworthy is the partnership ecosystem involved, including tier-one manufacturers like Mercedes-Benz, Siemens, and Bosch. These relationships validate the technology's potential market acceptance and provide established channels for commercial deployment. The five-year, publicly-funded project also demonstrates Constellium's ability to secure long-term development resources.
The Digital Fingerprint innovation project—creating digital twins for aluminum components—further enhances Constellium's value proposition. This technology enables predictive maintenance capabilities and data-driven manufacturing, potentially creating recurring revenue opportunities beyond initial component sales. The implementation in a Mercedes-Benz test vehicle suggests practical application readiness.
From a competitive standpoint, Constellium is differentiating through materials innovation that addresses multiple industry priorities: lightweighting, safety performance, design flexibility, and sustainability—with the HSA6™ alloys featuring significant recycled content. This multi-benefit approach could strengthen their position as automotive manufacturers increasingly need suppliers who can simultaneously solve weight, safety, and environmental challenges.
PARIS, July 15, 2025 (GLOBE NEWSWIRE) -- Constellium SE (NYSE: CSTM) is proud to announce the successful completion and publication of the FlexCAR project, its latest innovation effort with ARENA2036*, Germany’s leading research campus for future mobility and production technologies.
The FlexCAR platform envisions a future where major vehicle systems—such as the drivetrain, energy storage, and interior—can be easily configured or updated. Constellium worked alongside project partners such as Mercedes-Benz, Siemens, Bosch, and the German Aerospace Center (DLR) to complete this publicly funded, five-year project.
To help ensure that the structural backbone of this open architecture meets the highest standards in safety and performance, Constellium developed a modular sill concept using aluminum extrusions made from Constellium HSA6™ high-strength aluminum alloys featuring significant recycled content. Designed to support various powertrains—including battery electric and hydrogen fuel cell—the sill structure offers enhanced crash performance, design flexibility, and a lower carbon footprint over the vehicle’s lifecycle.
“FlexCAR shows how modular thinking—combined with the performance and sustainability benefits of aluminum—can revolutionize vehicle design, enabling longer lifespans, greater adaptability, and lower environmental impact,” said Patrick Böhler, Director of Sales & Product Development for Constellium Automotive Structures. “Collaborations like these are how we turn ideas into real-world innovations.”
Constellium also previously collaborated with ARENA2036 on the Digital Fingerprint innovation project, developing a digital twin of an aluminum component that tracks its performance across its full lifecycle—from design and production to on-road use and end-of-life. As part of this project, completed in 2024, Constellium engineered a smart aluminum housing for a power control unit, embedding sensors to collect crash and field data in a Mercedes-Benz test vehicle. This approach supports predictive maintenance, accelerates development cycles, and unlocks the full potential of connected, data-driven manufacturing.
Constellium is a full-service supplier of rolled and extrusion-based aluminum solutions for the global automotive market. We help automakers produce lighter, safer, and more fuel-efficient vehicles, as well as electric vehicles with greater range.
*ARENA2036 (Active Research Environment for the Next Generation of Automobiles) is a research campus in Stuttgart-Vaihingen, Germany designed as a highly flexible and future-oriented research platform for mobility and production. Constellium has been a contributing member since 2018.
About Constellium
Constellium (NYSE: CSTM) is a global sector leader that develops innovative, value-added aluminum products for a broad scope of markets and applications, including aerospace, packaging and automotive. Constellium generated
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